Optimizing Your Existing Facility Layout for Maximum Density

Commercial rent and land costs are fixed at record highs, and the cost of building new space is often too high to justify. Many manufacturing and warehouse leaders feel they have run out of room, yet the budget for expansion simply isn't there.

The good news is that you likely have more space than you realize. 

By focusing on a smarter facility layout, you can unlock hidden capacity within your current footprint. This approach allows you to increase storage and production volume while effectively lowering your cost per square foot.

Navigating Economic Headwinds

High operational costs for energy, raw materials, and labor are shrinking margins. At the same time, high interest rates make it difficult to finance new construction or major growth. 

These economic headwinds require a shift in strategy. Instead of looking outward for more land, successful firms are looking inward at their own floor plans.

A technical review of your operations can identify areas where space is wasted. Whether it is an inefficient assembly line or under-utilized vertical space in a warehouse, these gaps represent lost profit. Proper industrial design helps mitigate financial risk by ensuring every square inch of your facility contributes to the bottom line.

To combat these challenges, consider how layout optimization addresses specific financial pain points:

• Fixed Real Estate Costs: When you cannot change your rent or mortgage, the only way to improve your margin is to produce more within that same space.

• Reduced Capital Expenditures: Optimizing a current site is significantly cheaper than the ground-up construction of a new building or the logistical nightmare of moving.

• Energy Efficiency: A tighter, more logical layout often reduces the distance materials travel, leading to lower energy consumption for forklifts and conveyors.

• Regulatory Compliance Costs: Integrated engineering ensures that as you add density, you remain compliant with Ontario standards, avoiding the heavy fines associated with improper equipment placement or safety violations.

Precision Through 3D Modeling and Scanning

The most effective way to find extra space is to use advanced digital tools. Traditional 2D drawings often miss the fine details of a building, such as overhead pipes, electrical conduits, or structural beams. This is where 3D laser scanning becomes essential.

At Design Systems Canada (DSC), we use 3D laser scanning to capture the exact reality of your facility. 

This creates a highly accurate digital map, known as a point cloud. Once we have this data, we use 3D modeling to test new configurations in a virtual environment.

• Visualize Vertical Growth: 3D modeling allows us to see how high-bay racking or mezzanines will fit without hitting ceiling obstructions.

• Reduce Installation Risk: By designing in a 3D space, we ensure that new equipment will fit perfectly on the first try, preventing costly mistakes during site installation.

• Simulate Workflow: We can run simulations to see how people and materials move through the new facility layout, ensuring that higher density does not lead to traffic jams on the shop floor.

Maximizing Your Assets with DSC

Since 1983, Design Systems has helped companies across North America solve complex engineering challenges. 

Our services in Facility Layout & Design and Warehouse & Distribution are designed to address your specific pain points. We do not just move machines; we integrate Industry 4.0 solutions, ensure your electrical systems are safe through arc flash studies, and help you remain compliant with Ontario safety regulations.

By optimizing your current space, you can delay or even eliminate the need for a costly move. This strategy keeps your overhead low and your production high, giving you a competitive edge even in a tough economy.

Take the Next Step Toward Efficiency

Are you ready to see how much more your current facility can do? Don't let high real estate costs stall your growth. 

Contact Design Systems Canada today to speak with our engineering experts about a custom layout analysis.

Visit our website to explore our award-winning projects and learn more about our full suite of industrial engineering services. Let us help you turn your existing footprint into your most valuable asset.